Self-set magnesium carbonate composition and method of effecting setting thereof



I06. Gan lion? Examiner COATING R PLASTIC.

UNITED STATES PATENT OFFICE SELF-SET MAGNESIUM OARBONATE COM- POSITION AND METHOD OF EFFECTING SETTING THEREOF Samuel A. Abrahams, San Francisco, and Rubin Lewon, Menlo Park, CaliL, assignors to Plant Rubber & Asbestos Works, San Francisco,

Calif., a corporation of California No Drawing.

16 Claims.

Our invention relates to magnesium carbonate compositions, and more particularly to an improved method for effecting setting of a slurry Application March 8, 1939, Serial No. 260,663

tai ning a suspension of magnesium hydroxide In commercial practice, the magnesium hydroxide suspension is generally formed by treating containing gnesium garbonate prepared to with water calcin ed magnesite (a natural ocpossess self-setting properties'and to an improved curring magnesilini Carbonate) e e final product. This application is a continuation rniticg aterial (a natural occurring mineral comin part of our co-pending application, Serial posed essentially of calcium carbonate and mag- 'No. 212,697, filed June 9, 1938. nesium carbonate). In such method, the pre:

n n a nding application cipitation oi the self-setting carbonate oi mag- 1 Serial No. 2112,698, filed June 9, 1938, we have ng iprncrystals oeeursas the gassing with carbon 1 disclosed a type of method whereby such selfdioxide-containing gas proceeds. setting magnesium carbonate may be prepared. Care should be taken that the temperature of Briefly, such type of method comprises precipthe reaction does not get too high because if it itating comparatively fine needle-like magnesium does the self-setting prop of the magnesium carbonate crystals in an aqueous vefiidl r carbonate crystals would be impaired, if not de- 15 stunner a magnesium monndfsnen as sea stroyed. For best results, the reaction should w ater bittern. with a ,Qarbonate salt, snares also be controlled to convert substantially all of sgdium carbgnate, In this crystalline form, the the magnesium ions in the reacting medium to magnesium carbonate possesses self-setting propthe d s ri d crystalline a at f ma n sium,

2o erties. Care is taken during the reaction to preas the presenee'of magnesium in a form other 20 vent total or partial destruction of such crystals than he ne needle-like crystals impairs e after they form, which destruction would occur setting properties of the product. As with reshould the reaction be conducted at too high a p t t the formation f su a n s um cartemperature, resulting in loss or impairment of bonate crystals by reaction 01 me-gnesillm 0 mtheir self-setting properties. Excessive agitation pound with a carbonate salt in an aqueous ve- 25 durinFth reaction has been found to expedite l d y the decomposition f a agnesium t formation of such crystals, and is comebicarbonate solution, excessive agitation will enquently employed The magnesium carbonate hance the formation thereof in the gassing methcrystals having most desirable self-setting properties for subsequent employment in the manu- A Suitable temperature range conducting facture of insulating products, when examined the gass ng n is between y-e ght deunder the microscope, will usually range from grees Fahrenheit (68 F.) and one hundred four A about twenty (20) to fifty (50) microns in length degrees Fahrenheit (104 F.) preferably at about 1 and from about two (2) to live (5) microns in ei y-six de ees ahrenheit (86 F.); t e quanthickness tity of water being preferably from fifteen (15) 86 1/ Our assignees co-pending application, Serial parts to as high as Sixty p ts per part of No. 212,696, filed June 9, 1938, discloses another magnesium Ox de. by wei httype of method whereby the described self-setting In the 6888 where dolomitic material is used as magnesium carbonate crystals may be obtained a source of raw material, the inherent lightness Fyde'c'om'position of an aqueous solution of rnag: of the final product resulting from the self-setm nesium bicarbonate. Briefly, su'ch decomposition e properties e e ab es a slurry containis'efiect'ed' by excessively agitating the magnesium ing both the calcium carbonate which is insoluble bicarbonate solution and simultaneously applyd the self-Setting magnesium Carbonate 7 ing heat, to thus drive oiT carbon dioxide, which tals, to be set as such. In other words, the

results in the precipitation of the self-setting calcium carbonate need not be removed fo the I magnesium carbonate crystals Care is also production of a satisfactory light weight heat intaken during formation of the'crystals to presulating block, as is required in other commercial elude total or partial destruction thereof by too pressure molding Processes W e e dolomitic mahigh a temperature. Addition of active or terial is the source of raw material.

paustic magnesium oxide to the magnesium bi- From the preceding, it is seen that at some U carbonate solution, has been found to hasten the po t du e p a o o a c rbonate or decomposition reaction. magnesium by a reaction, in an aqueous reaction Such self-setting magnesium carbonate crystals vehicle, which consists essentially of the com- 1 may be also formed by g a ss i n g gvith carbon bination of magnesium and carbonate ions, a predi o iii de-co n tain ing gas an aqueous vehiclejconfcipitate of comparatively fine or thin needlelike crystals of magnesium carbonate is formed; and this crystalline magnesium carbonate which is a normal hydrated magnesium carbonate, believd'tobe'the trihydrate, has sglf setting i roperties. In thisTdr'i'nection, it is desirable to obtain relatively small needle-like crystals because these have been found to provide greater strength in the final product than that obtainable by larger crystals. Excessive agitation will produce the desirable smaller crystals which for most desirable self-setting properties for subsequent employment in the manufacture of insulating products, will usually range from about twenty (20) to fifty (50) microns in length and from about two (2) to five (5) microns in thickness, as was previously mentioned. I

If a slurry of such normal hydrated magnesium carbonate crystals ls"ca'st"or poured into 'a'form. "oi-moldfthe composition will set in a quiescent state to provide a self-set final product; the setting in the mold being materially expedited by application of heat. The composition has substantially no shrinkage upon setting; and no mechanical pressure need be applied thereto, as

nesium carbonate is usually molded under mechanical pressure in a filter mold, simultaneously with the expulsion of water therefrom through perforations in such filter mold. As a result, the density of the self-set product may be governed by the quantity of water left in the slurry which is poured into the mold, and such mold need not be perforated.

The usual types of reenforcing materials, such as asbestos or other suitable reenforcing fiber, in an amb'fint sufficient to provide a final product which contains from ten percent. (10%) to fifteen percent. (15%) by weight of the fiber, may be intermixed with the slurry to be set; such product being generally that employed commerciallyfor heat insulating purposes. Other chemically inactive solid bodies, such as vermiculite or diatgmaceous earth, may be alsa nfixed in th slurry. Such inert filler or reenforcing fiber may be mixed directly in the slurry after it is formed, or if desired, they may be incorporated in the reaction vehicle in which the self-setting magnesium carbonate crystals are formed.

We have found that certain conditions of alkalinity of the slurry will enable control gf th e manganese "be'rfiiitsuh setting 'to' occur fiTc'ir expeditiously as well as impart increased strength to the final product; and, if the setting is conducted under special controlled conditions, a superior grade product will result. Also, we have found that the slurry before being cast into a form or mold wherein it is to be set, may be preheated to cooperate in hastening the time of setting in the form. Our invention, therefore, has as its objects, among others, the provision of improvements in the product and in the manner'of obtaining setting of the described self-setting magnesium carbonate crystals. Other objects of the invention will become apparent from a perusal of the following deeclipticnMtlaereef.----

In .general, we..have found that if the slur he set of the ma nesium carbonate or stals to 5 not already marEEly alkaline ii. e. alkaline reserve sufficient to neutralize magnesium bicarfinfateienerally present in the Sllll'l'y and consume some of the carbon dioxide which is given off during the setting), the addition of a carbon dioxide consumi alkali thereto in a quant ty -7 simclent to render the Qfirry markedly alkaline,

is necessary in other methods, wherein the mag-,

cast therein. Also, we 'fo'untf tliit' ""s'e't ting is best conducted in an environment wherein substantially no drying or dehydration of the setting mas e, new, loss in weight thereof. This helps to preclude any shrinkage which might tend to occur. Drying of the set reduct is effected by a separate-55dindependentsubsequent step. With respect to forms wherein a comparatively large surface area of the setting mass is exposed so that moisture can readily evaporate from such exposed area, such as open pans, the setting to accomplish the best results should be in an enclosed chamber substantially free of drafts to the outside atmosphere and which is moisture-laden to the point where the atmosphere under which the setting occurs is substantially moisture-saturated with respect to the vapor pressure of the water in the mass being set, to preclude evaporation of moisture from the setting mass. The same effect may be obtained in an open space when forms are employed which enclose substantially all of the surface area of the setting mass, such as a tube-like form in which the setting mass is exposed only at an end of the form. In this event, substantially no moisture can evaporate during the setting period, and such forms, therefore, provide the means for precluding drying or dehydration of the setting mass. Steam can be employed as the source of heat wh'eh'forms of the latter type are utilized but any other suitable heat may be employed if desired.

Although all the steps of heating the slurry before it is cast into the form, utilizing a markedly alkaline slurry, and conducting the setting in an environment wherein drying of the setting mass is precluded, are employed, the step of uct. Also, the step of setting the slurry without substantial dehydration in a substantially nondrying atmosphere, may be omitted, and still produce a good product. The step of preheating ghe slurry prior to pouring it into the'foi'ms' is esira e ecause it enables the setting to be conducted in a shorter time, thereby making for economy of manufacture. However, such step ma be omitted without effecting the quality of tfiennai pro'd'fict. For the production of a superior product, the setting should be conducted under the described conditions wherein substantially no drying of the setting mass can occur and the slurry is rendered markedly alkaline. In addition to effecting the quality of the final product, the markedly alkaline slurry, as previously pointed out, permits expedition of the setting. Therefore, the combination of this step and the preheating step are important in obtaining a fast set.

Our improved method of setting the slurry containing the described self-setting needle-like magnesium carbonate crystals will now be described in greater detail. Such magnesium carbonate is a normal hydrated ma nesium carbonate, believed E Be the trihydrate, which sets 106. COMPOSITIONS,

COATING R PLASTIC.

Examiner nesium carbonate crystals during the period between the termination of the reaction by which they are formed and prior to the setting thereof in the forms or molds. We have now found 5 that heat may be applied during this period without weakening the final set of the product in the molds, provided the temperature and time are below the critical point at which the normal carbonate commences to undergo conversion to a basic carbonate. If the preheating temperature is too high, such conversion will occur in a relatively short time, while if the temperature is low but applied over a relatively long time, the conversion will also occur. The skilled operator can readily ascertain when such conversion commences because when it does the slurry starts to thicken or gel. Any reheatin gig tge slurry before it is poured into ihe forms s o d," ere ore, be below the point at which incipient c erSiO l- A- 5,

"" preheating arid; s uiryaftef ifls f rmed and before being poured into the molds is desirable to the setting is believed to enter into a reaction with other substances existing in the setting slurry. For any given setting conditions, the length of time of the set may 'be regulated by the quantity of the carbon dioxide-consuming 5 alkali which may be added to the slurry; the more alkali added within practical limits, the faster being the set permitted. In this connection, the carbon dioxide-consuming alkali also permits faster setting than would otherwise be 10 permitted with respect to any given slurry which does not have the carbon dioxide-consuming alkali therein because it allows the setting to be conducted at higher temperatures, to thereby hasten the conversion to a basic carbonate. 15

If only ma nesium oxid,e. is added, usually an amount thereof ranging from one percent. (1% 15a tel pgrgen 510%) by Weight of 'fii'agn'e's'iiim carbonate in he 'slurry will suflice. Borax, being a stronger alkali, is added in mum I0 ranging from one EEQLJl-YQLHLMQ...9Q;- cent. (2%) by weight of magnesium carbonate.

for commerical reasons because it enables the An alkali metal hydroxide, such as S di setting time to be materiall sho I,

resairrngireeaeea oiir'i afiiifacture. The preheating should be conducted to bring all of the slurry to a substantially uniform temperature as quickly as possible before pouring into the molds. This can be best accomplished by heating relatively small batches of the slurry,

and simultaneously stirring or mixing such batches to provide the uniform incorporation of the heat. The preheating may be conducted in open heated vessels if so desired; or by conveying the slurry through heated screw conveyors which serve to mix the slurry as well as convey it. Although conversion of the slurry to a basic magnesium carbonate will occur at widely varying temperatures, depending on the 40 character of the self-settable normal magnesium carbonate crystals, we have found that in most cases such conversion occgr sfmm at a temperature o a u one un red thirty degrees Fahrenheit (130 g g ta one hundred seventy degrees Fah'i'en eit (17g It is generally desirable to employmmg preheated which take about ten (10) to fifteen (15) minutes to bring all of the slurry up to the desired preheating temperature. It is undesirable to have conversion from the self-settable normalhydrated magnesium carbonate crystals to a basic magnesium carbonate, occur during the preheating because the entire setting should occur in the molds to provide a final product of maximum strength. As was previously pointed out, the

preheating step may be omitted, if so desired.

To hasten and also control the setting of the slurry containing such crystals whether it is or is not preheated, and at the same time increase the strength of the final product, we preferably render it markedly alkaline, if it is not already markedly a a me, y adding thereto either prior or after preheating if employed, or to the vehicle from which it is formed, an excess gf an alkali having the property of consurn ng'carbon oggide which m y a s r Tefition, such as preferably caustic or active magnesium oxide, i. e.. magnem is not dead Burnt, borax, or an a a me al hydroxide such as sodium hydroxide, or any suitaBle mixtures t ereo n a a such as lime may also be employed, but is not desirable Because it would adulterate the final product to too great an extent. The carbon dioxide-consuming alkali which is added to the slurry prior droxide being still stronger, is emp oye an amount ranging from one: t er rt l 1 ofonepercent 25 (0.1%; tp onelpercent zqfz f by weight of magnesium carbonate in the slurry. Magnesium oxide has the advantage of not adulterating the product at all, and, therefore, provides-for greatest added strength. The stronger alkalies, such 30 as borax and sodium hydroxide, however, permit faster setting. Therefore, a mixture of magnesium oxide and borax or an alkali metal hydroxide, produces ideal results. Such mixture may contain these substances in any desirable pro- 35 portions.

The upper limit of the amount of alkali which should be added is not particularly critical, as the maximum quantity may be determined at the time by one skilled in the art, in 40 accordance with the conditions. It is only important that the slurry be made markedly alkaline, that is, sufliciently alkaline to neutralize any magnesium bicarbonate present, which has the unfortunate property of inhibiting the set and 45 is consequently undesirable, and provide a reserve to consume some of the carbon dioxide which is evolved during setting. In the setting operation, theslurry is cast or poured directly Agitation"of"me sci g ma'iri siiifif'car bonate crystals in the mold is avoided because such agitation will impair the setting of the product. Hence, the setting in the mold is accomplished with the crystals in a quiescent state. As was previously related, the composition sets with substantially no shrinkage and no pressure need be applied to it to accomplish the setting. As a result, the density of the final product is gov erned by the quantity of water left in the slurry which is poured into the mold. It is to be understood that the self-settable normal hydrated 65 magnesium carbonate 'cry'stalline"'preci itate is not aiiowa to set in the reaction ve icle and that such reaction vehicle usually contains an excess of water, a desired amount of which is usually removed, in any suitable way such as by de- 70 cantation or filtration, to determine the density of the final product. More water than desired is usually removed when the precipitate is separated from the reaction vehicle, for example for the purpose of washing it, but additional water 75 may be added afterwards to provide a final product of the desired density.

During the setting, we have found that carbon dioxide gas is given off; and microscopic observation of the set product shows that the magnesium carbonate which was originally all comparatively thin or fine needle-like crystals now consists essentially of a new crystal form. Some of the original needlalilie'ci'ystals may remain, but a new, very small crystal appears. Such new crystal tends to cluster into grape-like groups, or to adhere to the surface of the needle-like crystals. This probably accounts for the great strength of the final product which breaks with a clean fracture, in contradistinction to the product of the prior processes wherein pressure molding is employed, which mushes upon being broken, thus indicating that the product of our invention is bonded by the interlacing of the crystals.

Because of the evolution of the carbon dioxide gas and the formation of the new crystals, a reaction occurs in which the carbonate of magne s ium is converted into a li'ghtfbasic magnesium carbonate. The-carbon dioxide-consuming alkali 'which is' preferably added to the slurry prior to the setting operation, allows hastening and control of the setting which is preferably conducted in an enclosed chamber when the molds are of such character as to expose a relatively large surface area of the setting mass, such as open pans, not only because the setting can occur faster when the slurry is made markedly alkaline, but also because the consumption of some of the carbon dioxide reduces the carbon dioxide pressure in such setting mass, and thus by the principle of the law of mass action, causes the reaction to proceed faster toward the side of the set product. Also, such alkali since it consumes carbon dioxide, controls the rate of evolution thereof and precludes formation of fissures in the interior of the setting product, which might otherwise result from too rapid an evolution of the carbon dioxide, with consequent weakening of me anin product.

Although no pressure is required to compact or mold the material, since the material sets in a quiescent state independent of pressure, pressure molding may be employed and still pr uce 'roduct, or a special dense product for certain purposes. However, such pressure molding is preferably omitted inasmuch as it would increlsmmthe final product, which is undesirable where the product is to be employed for heat insulating purposes. Inasmuch as pressure molding has heretofore been necessary because the magnesium carbonate produced by other methods does not have selfsetting properties, and because pressure may be applied to the self-settable magnesium carbonate of our invention but is not necessary, the expression "independent of pressure is employed here inafter to describe that the magnesium carbonate of our invention has self-setting properties not conditioned on pressure.

When preheating of the slurry is not employed and the molds are of such character as to expose a relatively large surface area of the setting mass, the temperature applied to the molds during the setting should not be too high or applied too rapidly, because, although the product will set, the evolution of gas may be so rapid as to leave the final product with gas holes. Neither should the temperature be too low, because then the setting is, generally speaklng, too slow for practical purposes. A suitable temperature range under atmospheric pressure is substantially from one hundred forty degrees Fahrenheit (140 F,! to

one hundred ninety-five degrees a renheit (195 F.). At this temperature range, the setting t6 hard cake in molds which expose a relatively large surface area of the product will usually occur in from one-half to three to 3) hours, the time varying, of course, with the temperature actually applied, and also with the chemical and physical character of the composition, as well as the thickness of the mass. If the slurry is preheated, and also markedly alkaline, the setting in molds which expose a relatively large surface area of the product, can be accomplished in about three to fifteen (3 to 15) minutes at a lower temperature of about one hundred thirty degrees Fahrenheit (130 F.) to one hundred seventy degrees Fahrenheit (170 F.)

For best results, it is important that the setting be conducted so that substantially mying oriehydration I of the composition occurs during e setting thereof, as this minimizes shrinkage should the" setting product have any tendency to shrink. For this reason, we effect the setting in our improved method when the product is cast into molds which expose a relatively large surface area of the product, by placing the slurryfilled molds in an enclosure or chamber maintained at the desired temperature by liv t steam introduced therein under pres'sfi ermore, it is important that the enclosure in which the setting is conducted be free of any substantial drafts to the outside atmosphere because drafts might cause carrying of moisture P from the product as it sets, and this might cause undesirable drying which might result in shrinkage. By employing live steam as the heating medium for effecting the setting in the molds, the region or atmosphere in which the setting occurs can be made moisture-saturated or oversaturated with respect to the vapor pressure of the water in the setting material, to thereby minimize evaporation of moisture therefrom and avoid shrinkage. Under the prescribed setting conditions, the slurry after it has set in the mold and before it is dried by a subsequent drying step to be described, will weigh substantially the same as it did when first cast into the mold.

Instead of live steam as a source of heat, the same effect may be obtained by using an external source of heat to heat the chamber in m mgis" conducted, and by introducing a spray or other source of water into the chamber to render the atmos here, therein moisture-laden. However, steam is preferred Because it penetrates the setting mass to thereby replace more readily any moisture which might tend to be driven off because of the heat. If molds are employed which substantially completely jacket the slurry, such as a tube-like mold wherein the slurry is only exposed at an end of the mold, then such type of mold serves by itself to preclude substantial evaporation of moisture during the setting, and causes the setting to occur under non-drying conditions. Although steam heat may be employed for heating such form or mold, it is not necessary, as any other suitable kind of heat may be utilized instead. Furthermore, this type of mold, particularly if the slurry is preheated and contains the carbon dioxide-consuming alkali, allows the heat to be applied directly over a large area-of the slurry, permitting an extremely fast set.

After having set in molds, the blocks or slabs I06. COMPOSITIONS,

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commercial processes where pressure molding is W ite fort which are formed are self-supporting before they are dry and while containing substantially the same amount of moisture as in the slurry before it has set. The blocks or slabs formed in other necessary are not self-supporting, and consequently have to be supported in frames after they are removed from the molds, so that they will not break during handling prior to drying thereof.

Upon removal of the slabs or blocks from the molds after setting thereof, they are next dried in the usual manner heretofore employed'ming the mechanically molded product. Such drying is accomplished, usually, in conventional dry ing ovens at a temperature ranging from one hundred fifty-five degrees Fahrenheit (155 F.) to three hundred ninety-five degrees a ren e (3951 52) to remove all uncombined or free water ng as water of crystallization. Depending on the temperature and the draft, it will take from twenty-four to seventy-two;- (2g tg 72) hog? for the ,dr The drying, if esir may E- a tying, Eu 0v? I preferred because it s er. Silo d the" material tend to stick to the molds upon removal therefrom, the molds may be first greased with any suitable substance, such as petroleum grease.

Even though there is substantially no shrinkage of the material in the molds, it may be desirable to mill or trim the surfaces of the dried prod not so as to provide an attractive product not marred with surface imperfections. This is particularly true with respect to the type of molds, such as an open pan, wherein a relatively large surface area of the slurry is uncovered or exposed, as the exposed area tends to leave a surface which is not smooth. Not over ten percent. (10%) of Examiner cubic foot; the spgific gra vity, therefore, ranging tion will, thus, average fro 'u ter than respon ng pro uc prouce rmer methods; and even though lighter, it much stronger. This comparison between eighty-five percent. (85%) magnesium carbonate blocks of our invention and those heretofore produced holds true for any given specification of materials and percentages of magnesium carbonate in the respective blocks. Because of the lightness of the product of our invention, considerable saving in freight charges obtains. Also, due to the low density of our product, it has a lower heat conductivity coefilcient than that of products produced by former methods. The heat conductivity coefficient of the product of our invention weighing about ten to twelve pounds (10 to 12 lbs.) per cubic foot will run about twenty percent. (20%) to thirty percent. (30%) lower than the product produced by former methods and weighing about sixteen to eighteen pounds (16 to 18 lbs.) per cubic foot.

Although the product of our invention is lighter, it is much stronger than heretofore produced products. Weight for weight, it is fifty percent (50%) to one hundred percent. (100%) stronger; while a block of our invention, for example an eighty-five percent (85%) magnesium carbonate block weighing eleven pounds (11 lbs.) percubic foot, will be as strong or even stronger than the corresponding block produced by former methods and averaging sixteen to eighteen pounds (16 to 18 lbs.) per cubic foot.

As was previously related, where olomitic the product need be removed by such milling terial is the source of raw material, the s. when molds which expose a relatively large area carbonate may be left in the slurry containin of the slurry are employed, whereas with products produced by other methods wherein molding under pressure is required, the amount of product removed by milling runs from thirty percent.

(30%) to forty percent. (40%). The milled-g3 W e se -se ing magne m car ona crystals, subsequently treated by our preferred method to effect setting thereof, and still produce a satisfactory light-weight block adapted for heat insulating purposes. In this connection, the dolomaterial is not entirely waste material because it mitic product resulting from the method of our may e. use d f o1; ma ng magne a insulating eefr'i erft. 'HQTZ v er, it has less value as a cement, and therefore results in an economic loss. Hence, because of the lesser amount of material which need be trimmed from the block or slab of our invention when molds which expose a relatively large area of the slurry are employed, a further economy results. Because the product of our invention sets in a quiescent state substantially without shrinkage, the molds may be made of special shapes so as to form correspondingly shaped insulating fittings.

Standard commercial products of magnesium carbonate insulating blocks produced by former pressure molding methods contain about eightyfive percent by weight of basic magnesium carbonate as a bonding agent and -about fifteen percent. (15%) by weight of asbestos fiber to reenforce the product. Undef pi ''siii'. standards, such blocks weigh from sixteen to eighteen pounds (16 to 18 lbs.) per cubic foot; the specific gravity, therefore, ranging from twenty-five one-hundredths (.25) to twenty-eight one-hundredths (.28). By adjustment of the water content of the slurry prior to casting it into the mold, the similar product of our invention containing the same percentages of basic magnesium carbonate and asbestos fiber can be made to weigh as low as nine pounds (9 lbs.) per cubic foot, and will average from ten to twelve pounds (10 to 12 lbs.) per invention and containing the same percentage of asbestos fiber as occurs in the standard commercial magnesium heat-insulating blocks produced by former pressure molding methods, and in which calcium carbonate is not eliminated, can be made to weigh as low as twelve to sixteen pounds (12 to 16 lbs.) per cubic foot (the specific gravity, hence, ranging from about one hundred ninety-two one-thousandths (.192) to two hundred fifty-six one-thousandths (.256) In addition to lightness the dolomitic product possesses greater strength and has higher insulating efficiency than the product produced by other commercial methods involving pressure molding, even though, in such other methods, the calcium compounds are eliminated from the source of dolomitic material. For example, a block formed by the method of our invention, weighing about thermore, although the product is shaped, it is not stony or rock-like in character as are artiiicial stones or natural rocks, but is balk-like in character. In other words, comparza tban "artificial stone or natural rock, it is relatively soft org (Walls; the material being readily rufiefi' 01h the surface thereof. However, insofar as magnesia insulation is concerned, the final dried product of our invention is relatively hard and firm or rigid, with sumcient strength and cohesive bonding power to provide a modulus of rupture (flexure strength) enabling such product to be entirely self-supporting in slabs as thin as one (1) inch and as long as three (3) feet. Such strength is necessary for allowing the material to be handled and applied. Not only is the final dried product self-supporting but, as previously explained, the set product prior to drying is also self-supporting.

The results of our invention are obtainable, irrespective of whether or not the composition to be set consists essentially of the self-setting, normal hydrated magnesium carbonate crystals alone or of such magnesium carbonate crystals intermixed with other materials. Therefore, in the appended claims, the expression magnesium carbonate composition includes compositions, such as the dolomitic composition described, which contain materials in addition to magnesium carbonate.

We claim:

1. In the method of producing a self-set magnesium carbonate composition from a slurry containing normal magnesium carbonate crystals having self-setting properties independent of application of pressure, said composition being capable of use as a heat insulating material, the step of enhancing setting of such slurry by adding an alkali thereto to consume carbon dioxide which is evolved during the setting.

2. In the method of producing a self-set magnesium carbonate composition from a slurry containing normal magnesium carbonate crystals having self-setting properties independent of application of pressure, said composition being capable of use as a heat insulating material, the step of enhancing setting of such slurry by adding magnesium oxide thereto to consume carbon dioxide which is evolved during the setting.

3. In the method of producing a self-set magnesium carbonate composition from a slurry containing precipitated normal magnesium carbonate crystals having self-setting properties independent of application of pressure, said composition being capable of use as a heat insulating material, the step of incorporating borax in such slurry.

4. In the method of producing a self-set magnesium carbonate composition from a slurry containing precipitated normal magnesium carbonate crystals having self-setting properties independent of application of pressure, said composition being capable of use as a heat insulating material, the step of incorporating an alkali metal ydroxide in such slurry.

5. A molded light weight cellular chalk-like but substantially rigid and self-supporting basic magnesium carbonate composition capable of use as a heat insulating material and self-set substantially without shrinkage independent of application of pressure from normal magnesium carbonate crystals having self-setting properties, said composition being strengthened by the product resulting from the addition thereto of a carbon dioxide-consuming alkali.

6. A molded light weight cellular chalk-like but substantially rigid and self-supporting basic magnesium carbonate composition capable of use as a heat insulating material and self-set substantially without shrinkage independent of application of pressure from normal magnesium carbonate crystals having self-setting properties, said composition being strengthened by the product resulting from the addition thereto of the magnesium oxide.

'7. A molded light weight cellular chalk-like but substantially rigid and self-supporting basic magnesium carbonate composition capable of use as a heat insulating material and self -set substantially without shrinkage independent of application of pressure from normal magnesium carbonate crystals having self-setting properties, said composition being strengthened by the product resulting from the addition thereto of borax.

8. A molded light weight cellular chalk-like but substantially rigid and self-supporting basic magnesium carbonate composition capable of use as a heat insulating material and self-set substantially without shrinkage independent of application of pressure from normal magnesium carbonate crystals having self-setting properties, said composition being strengthened by the product resulting from the addition thereto of an alkali metal hydroxide.

9. A magnesium carbonate composition capable for the preparation of heat insulating material and having self-setting properties independent of application of pressure comprising a self-settable slurry containing needle-like crystals of normal magnesium carbonate having self-setting properties, said slurry also having sufficient alkali added thereto to neutralize any magnesium bicarbonate which may occur therein and consume carbon dioxide which is evolved during setting of the slurry.

10. The method of producing a self-set magnesium carbonate composition which comprises forming in a reaction vehicle a precipitate of normal magnesium carbonate in the form of needle-like crystals having self-setting properties, without allowing setting of such precipitate in the reaction vehicle removing from the reaction vehicle a slurry containing such precipitate, incorporating a carbon dioxide-consuming alkali in said precipitate to allow the subsequent setting thereof to be expedited, eiiecting the setting by applying heat to the slurry, and drying the resultant product.

11. The method of producing a self-set molded magnesium carbonate composition which comprises forming in a reaction vehicle a precipitate of normal magnesium carbonate in the form or needle-like crystals having self-setting properties, without allowing setting of such precipitate in the reaction vehicle removing from the reaction vehicle a slurry containing such precipitate, incorporating a carbon dioxide-consuming alkali to allow the subsequent setting to be expedited, either before or after the incorporation of said carbon dioxide-consuming alkali preheating said slurry to cooperate in expediting the setting, casting the preheated slurry into a form adapted to shape said composition, efiecting the setting by applying heat to the slurry in the form, and drying the resultant product.

12. In the method of setting a magnesium carbonate composition by application of heat to a slurry containing normal magnesium carbonate in the form of needle-like crystals having selfsetting properties; the step of expediting the set- 106. COMPOSITIONS,

COATING R PLASTIC;

Mug uy reheating tne slurry prior to effecting setting thereof.

13. In the method of producing a self-set molded magnesium carbonate composition by application of heat to a slurry in a form adapted to shape the composition and which contains normal magnesium carbonate in the form of needle-like crystals having self-setting properties; the steps of expediting the setting by preheating the slurry prior to casting it into said form, and either before or after such preheating incorporating a carbon dioxide-consuming alkali.

14. A basic magnesium carbonate composition self-set independent of application of pressure by conversion from normal magnesium carbonate crystals having self-setting properties, said composition being strengthened by the product resulting from the addition thereto of a carbon dioxide-consuming alkali.

15. A molded light weight cellular chalk-like but substantially rigid and self-supporting basic magnesium carbonate heat insulating composition reenforced by asbestos fiber, self-set independent of application of pressure without shrinkage by conversion from normal magnesium carbonate crystals having self-setting properties; said composition being characterized by the absence of Patent no. 2,209,75h.

SAMUEL A. ABRAHAMS, ET AL.

txammer fissures resulting from the incorporation therein of a carbon dioxide-consuming alkali.

16. The method of producing a self-set basic magnesium carbonate composition capable of use as a heat insulating material which comprises forming in an aqueous reaction vehicle a precipitate of normal magnesium carbonate in the form of needle-like crystals having self-setting properties, without allowing setting of such precipitate in the reaction vehicle removing from the reaction vehicle a slurrycontaining such precipitate, adding suflicient alkali to neutralize any magnesium bicarbonate which may occur and to consume carbon dioxide which is evolved during the setting, either before or after the addition of said alkali preheating the slurry to cooperate in expediting the setting, casting the preheated slurry into a form adapted to shape said composition, effecting the setting by applying heat to the slurry in the form while simultaneously precluding evaporation of substantial amounts of moisture from the setting slurry to minimize shrinkage during the setting, and drying the resultant product.

SAMUEL A. ABRAHAMS. RUBIN LEWON.

CERTIFICALE' OF CORRECTION. a B

It is hereby certified that error appears in the printed specification July 50, 19110.

of the above numbered patent requiring correction as follows: Page 1, first column, line 10, for 2112,698" read "212,698"; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 17th day of September, -A. D. 1911.0.

(Seal) Henri Van Arsdale Acting Comm ssioner of Patents.

CERTIFICATE OF OORRECTIOiI.

Patent No. 2,209,7 h. July 50, who.

smmm. A. ABRAHAM-'5, ET AL.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 1, first colmnn, line 10, for "2112,698" read --212,698-; and that the said Lettera Patent should be read with this correction therein-that the acne may conform to the record of the case in the Patent Office.

Signed and sealed this 17th day of September, -A. D. 191m.

He Van Aradale (S Acting co m ieeioner of Patents. 

